Systems and procedures for configuring plant assembly stations

Abstract

Methods and systems for configuring a plant assembly station in a vehicle manufacturing plant are provided. Plant sensor data generated by a plant sensor system is received by a plant assembly station configuration system. This plant sensor data is linked to the configuration of a first plant assembly station in the vehicle manufacturing plant. A digital twin of the first plant assembly station is created, partly based on the plant sensor data. Based on a simulation-based evaluation of the digital twin of the first plant assembly station, a determination is made as to whether the configuration of the first plant assembly station complies with the operating regulations. Based on this determination, an operational capability status of the configuration of the first plant assembly station is generated.

Description

IntroductionThe technical field relates generally to vehicles and, more particularly, to systems and methods for configuring plant mounting stations.A vehicle manufacturing plant typically includes a plurality of plant mounting stations. The plant mounting stations are often reconfigured to accommodate changes in the production of various types of vehicles. Examples of vehicle types include a sedan and a pick-up truck. A vehicle product type may be a particular vehicle model. In many cases, when a vehicle manufacturing facility changes the type of vehicle to be manufactured, the vehicle manufacturing facility may be shut down for a longer time while reconfiguring the facility mounting station to assist in the production of the new type of vehicle.DE 10 2021 208 247 A1 describes a method for operating a modular production system and the modular production system. The production system has a control device, a production area, an electronic map of the production area and at least one production object for positioning on the production area. The electronic map has respective coordinate information about a plurality of permanently predefined node points of a grid projected onto the production surface. The method comprises electronically selecting at least one position node from the plurality of nodes by means of the control device, and positioning the at least one production object at a location on the production surface assigned to the coordinate information of the at least one electronically selected position node. The at least one production object can be positioned only at the location on the production surface which is assigned to one of the plurality of permanently predefined nodes of the electronic card.Accordingly, it is desirable to provide improved methods and systems for configuring plant mounting stations. Other desirable features and characteristics will become apparent from the following detailed description and appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.DESCRIPTION OF THE INVENTIONThe invention is defined by the claims.According to a first aspect of the invention, a method for automatically configuring a plant mounting station in a vehicle manufacturing plant is provided. The method includes identifying a vehicle product type for production at the vehicle manufacturing plant, receiving plant sensor data generated by a plant sensor system, the plant sensor data associated with a configuration of a first plant mounting station (104) at the vehicle manufacturing plant, generating a digital twin of the first plant mounting station based in part on the plant sensor data and the vehicle product type and conforming to operating rules, transmitting a configuration of the digital twin to a plant operating system, converting a configuration of the plant mounting station in accordance with the configuration of the digital twin by modifying at least one self-moving item of the plant mounting station via instructions provided from the plant operating system to the at least one self-moving item of the plant mounting station, wherein the instructions cause at least one of a change in the orientation of the item, a change in the location of the item, the swapping of a position of a first item with a position of a second item, a swapping of the at least one item, an adding of an item, and a removing of an item to configure the plant mounting station automatically. The method further includes receiving feedback from plant sensor data generated by the plant sensor system, the feedback including configuration of the plant mounting station generated in response to the instructions the plant operating system issues to the at least one self-moving asset of the plant mounting station, generating a digital twin of the plant mounting station based on the feedback from the plant sensor data, determining whether the configuration of the first plant mounting station matches the operating rules based on a simulation-based evaluation of the digital twin of the first plant mounting station, and generating an operability status of the configuration of the first plant mounting station based on the determination.According to a second aspect of the invention, there is provided a plant mounting station configuration system. The plant mounting station configuration system includes at least one processor and at least one memory communicatively coupled to the at least one processor. The at least one memory includes instructions that, when executed by the at least one processor, cause the at least one processor to perform the method described above.According to an embodiment, each of the plurality of self-propelled goods is one of an autonomous mobile robot, AMR, with plant equipment, an AMR with parts, an AMR with hoist, an AMR with parts mounted, and an AMR with station lighting.Brief Description of the DrawingsThe exemplary embodiments are described below in connection with the following drawings, wherein like numerals designate like elements, and wherein: FIG. 1 is a functional block diagram of a vehicle manufacturing plant including a plant mounting station configuration system, in accordance with at least one embodiment; FIG. 2 is a functional block diagram of a plant mounting station configuration system in accordance with at least one embodiment; FIG. 3 is a flow diagram representation of a method for configuring a plant mounting station to self-propelled articles using instructions provided by human workers, in accordance with at least one embodiment; FIG. 4 is a flow diagram representation of a method for automatically configuring a plant mounting station via a plant operating system that provides instructions for self-propelled articles in accordance with at least one embodiment; and FIG. 5 is a schematic illustration of examples of various levels of reconfiguration of a plant assembly plant that may be facilitated by a plant assembly station configuration system according to at least one embodiment.Detailed DescriptionThe following detailed description is merely exemplary in nature and is not intended to limit the application and use. Moreover, there is no intention to be bound by explicit or silent theories set forth in the foregoing technical field, background, brief summary, or the following detailed description. As used herein, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group), and memory that executes one or more software or firmware programs, combinatorial logic circuitry, and / or other suitable components that provide the described functionality.Embodiments of the present disclosure may be described herein in terms of functional and / or logical block components and various processing steps. Such block components may be implemented by any number of hardware, software, and / or firmware components configured to perform the specified functions. For example, an embodiment of the present disclosure may use various integrated circuit components, for example, memory elements, digital signal processing elements, logic elements, look-up tables, or the like, which may perform a variety of functions under the control of one or more microprocessors or other controllers. Moreover, those skilled in the art will appreciate that embodiments of the present disclosure may be used in connection with any number of systems and that the systems described herein are merely exemplary embodiments of the present disclosure.For brevity, conventional techniques associated with signal processing, data transmission, signaling, control, and other functional aspects of the systems (and the individual operating components of the systems) will not be described in detail herein. Moreover, the connection lines depicted in the various figures are intended to represent example functional relationships and / or physical couplings between the various elements. It should be appreciated that many alternative or additional functional relationships or physical connections may be present in an embodiment of the present disclosure.FIG. 1 illustrates a functional block diagram of a vehicle manufacturing plant 100 including a plant mounting station configuration system 102 in accordance with at least one embodiment. The vehicle manufacturing plant 100 includes a plant mounting station 104, a plant operating system 106, a plant sensor system 108, and the plant mounting station configuration system 102. While the vehicle manufacturing plant 100 is illustrated as a single plant mounting station 104, a vehicle manufacturing plant 100 typically includes a plurality of plant mounting stations 104. When a vehicle 110 is mounted in the vehicle manufacturing plant 100, various plant mounting stations 104 are configured to install various components into the vehicle 110. The plant mounting stations 104 are configured to produce a particular type of vehicle product. Examples of vehicle types include a sedan and a pick-up truck. In various embodiments, the vehicle product type specifies a vehicle model.In the vehicle manufacturing plant 100, a plurality of vehicles 110 may be mounted simultaneously. Different vehicles 110 may be populated with different vehicle components simultaneously at different plant mounting stations 104 of the plant. Each of the vehicles 110 may be located at a different point in the vehicle assembly process. The plant operating system 106 is configured to coordinate the manufacture of the vehicles 110 in the vehicle manufacturing plant 100. The plant operating system 106 is configured to coordinate the configuration / reconfiguration of the various plant mounting stations 104 in the vehicle manufacturing plant 100 to mount vehicles 110 with a particular type of vehicle product.Although a single central plant operating system 106 is shown, the vehicle manufacturing plant 100 may include a series of distributed plant operating systems that coordinate the mounting of vehicles 110 in the vehicle manufacturing plant 100. For example, the plant operating system 106 may include a plant control tower that communicates with a plurality of plant floor systems to coordinate the configuration / reconfiguration of the plant mounting stations 104 in the vehicle manufacturing plant 100. The plant operating system 106 is communicatively coupled to the plant mounting station configuration system 102.The plant sensor system 108 includes a plurality of plant sensors distributed throughout the vehicle manufacturing plant 100. An example of a plant sensor is a camera. The plant sensor system 108 is configured to generate plant sensor data associated with the configuration of the plant mounting station(s) 104 in the vehicle manufacturing plant 100. The plant sensor system 108 is communicatively coupled to the plant mounting station configuration system 102.The plant assembly station 104 comprises a plurality of self-moving articles and one or more fixed articles. Examples of self-propelled articles include, but are not limited to, an autonomous mobile robot (AMR) with equipment 112A, 112B, an AMR with hoist 114, an AMR with parts 116 mounted, an AMR with lighting 118, and an AMR with parts 120. An example of a fixed item of matter is the fixed equipment 122. The vehicle manufacturing plant 100 may include one or more plant structures 124. The positioning of the self-moving goods in the configuration of the plant assembly station 104 is based on the locations of the fixed equipment 122 and / or the plant structure(s) 124. Different plant mounting stations 104 in the vehicle manufacturing plant 100 may have different configurations.The plant mounting station configuration system 102 is configured to receive the plant sensor data generated by the plant sensor system 108. The plant sensor data is associated with the configuration of the plant mounting station 104. The plant mounting station configuration system 102 is configured to generate a digital twin of the plant mounting station 104DT based on the plant sensor data. The digital twin of the plant mounting station 104DT is a virtual representation of the physical configuration of the plant mounting station 104. The plant sensor system 108 provides a perception infrastructure that acts as a link to mirror the physical configuration of the physical plant mounting station 104 into a digital twin of the plant mounting station 104DT in the plant mounting station configuration system 102. The location of the self-moving articles 112A, 112B, 114, 116, 118, 120, the fixed articles 122, and / or the plant structure(s) 124 in the physical plant assembly station 104 is mirrored in the location of the digital twin representation of the self-moving articles 112A DT, 112B DT, 114 DT, 116 DT, 118 DT, 120 DT, the fixed article 122 DT, and / or the plant structure 124 DT in the digital twin of the plant assembly station 104 DT.In at least one embodiment, plant mounting station configuration system 102 is configured to generate a digital twin configuration of a new plant mounting station 104DT. The plant mounting station configuration system 102 is configured to facilitate the configuration of a new plant mounting station 104 in accordance with the digital twin configuration of the new plant mounting station 104DT based on plant sensor data received from the plant sensor system 108. In at least one embodiment, plant mounting station configuration system 102 is configured to generate a digital twin DT configuration of a displaced plant mounting station 104. The plant mounting station configuration system 102 is configured to facilitate the configuration of the laid plant mounting station 104 in accordance with the digital twin configuration of the laid plant mounting station 104DT based on the plant sensor data received from the plant sensor system 108.In at least one embodiment, plant mounting station configuration system 102 is configured to generate a digital twin configuration of a modified plant mounting station 104DT. The plant mounting station configuration system 102 is configured to facilitate the configuration of the modified plant mounting station 104 in accordance with the digital twin configuration of the modified plant mounting station 104DT based on plant sensor data received from the plant sensor system 108. Examples of modifications to the configuration of the plant mounting station 104 include, but are not limited to, changing the orientation of the item, changing the location of the item, swapping the position of a first item with the position of a second item, swapping the item, adding an item, and removing an item.In various embodiments, the modifications to the configuration of the plant mounting station 104 are implemented by instructions given by human workers to one or more of the self-propelled assets 112A, 112B, 114, 116, 118, 120 of the plant mounting station 104. In various embodiments, the modifications to the configuration of the plant mounting station 104 in accordance with the configuration of the modified twin digital plant mounting station 104DT are implemented via instructions that the plant operating system 106 issues to one or more of the self-moving assets 112A, 112B, 114, 116, 118, 120 of the plant mounting station 104.The plant mounting station configuration system 102 is configured to determine whether a configuration of the plant mounting station 104 meets the operating rules based on a simulation-based digital twin evaluation of the plant mounting station 104 DT. The plant mounting station configuration system 102 is configured to generate an operability status of the plant mounting station 104 based on the simulation-based digital twin evaluation of the plant mounting station 104DT. The configuration of the plant mounting station 104 has an operability status when the plant mounting station configuration system 102 determines that the configuration of the plant mounting station 104 meets the operating regulations.The configuration of the plant mounting station 104 does not have an operability status when the plant mounting station configuration system 102 determines that the configuration of the plant mounting station 104 does not conform to the operating rules. The plant mounting station configuration system 102 is configured to evaluate additional modifications to the plant mounting station 104 until the plant mounting station configuration system 102 determines that the configuration of the plant mounting station 104 meets operating rules.In at least one embodiment, plant mounting station configuration system 102 is configured to receive plant sensor data generated by plant sensor system 108. The plant sensor data is associated with configurations of a plurality of plant mounting stations 104 in the vehicle manufacturing plant 100. The plant mounting station configuration system 102 is configured to generate, based on the plant sensor data, a digital twin of the vehicle manufacturing plant that includes a plurality of digital twins of the plurality of plant mounting stations 104DT. The plant mounting station configuration system 102 is configured to determine whether the configuration of the vehicle manufacturing plant 100 meets operating rules based on a simulation-based digital twin evaluation of the vehicle manufacturing plant. The plant assembly station configuration system 102 is configured to transmit the digital twin of the vehicle manufacturing plant to the plant operating system 106 to allow the plant operating system 106 to transmit instructions to a plurality of self-moving assets of each of the plurality of plant assembly stations 104 to move according to the digital twin of the vehicle manufacturing plant to locations within the vehicle manufacturing plant 100.In at least one embodiment, digital twin of plant assembly station 104 generated by plant assembly station configuration system 102 includes DT component settings for one or more components of plant assembly station 104. The plant mounting station configuration system 102 is configured to transmit the digital twin of the plant mounting station 104 DT to the plant operating system 106 to enable the plant operating system 106 to transmit the component settings to the one or more components of the plant mounting station 104 in accordance with the digital twin of the first plant mounting station 104 DT. Examples of the components include station lighting, station equipment, and a station tool.FIG. 2 illustrates a functional block diagram of a plant mounting station configuration system 102 in accordance with at least one embodiment. The plant mounting station configuration system 102 includes at least one processor 200, at least one memory 202, and a communication system 204. The processor(s) 200 is / are communicatively coupled to the at least one memory 202 and the communication system 204. The processor(s) 200 is(are) a programmable device that includes one or more instructions stored in or associated with the at least one memory 202. The at least one memory 202 includes instructions that the processor(s) 200 is / are configured for execution.The at least one memory 202 is a computer readable storage device or medium. The processor(s) 200 may / may be any custom or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), a sub-processor among multiple processors, a semiconductor-based microprocessor (in the form of a microchip or chipset), a macroprocessor, any combination thereof, or generally any device for executing instructions. Computer readable storage devices or media may include volatile and nonvolatile memory, for example read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables while the processor(s) 200 is / are turned off. The computer readable storage device(s) may / may be implemented using any number of known storage devices, such as programmable read-only memory (PROMs), electrically PROM (EPROM), EEPROM (electrically erasable PROM), flash memory, or other electrical, magnetic, optical, or combined memory devices capable of storing data, some of which represent executable instructions, used by the plant mounting station configuration system 102. The instructions may include one or more separate programs, each of which includes an ordered listing of executable instructions for implementing logical functions. When executed by the processor(s) 200, they execute logic, calculations, methods, and / or algorithms to implement the configuration of plant mounting stations 104.The communication system 204 is configured to facilitate communication between the plant mounting station configuration system 102 and the plant operating systems 106. The at least one working memory 202 comprises a digital twin generator for installation assembly station 206 and an installation configuration evaluator 208. The plant mounting station configuration system 102 may include additional elements that facilitate operation of the plant mounting station configuration system 102.FIG. 3 illustrates a flow diagram of a method 300 for configuring a plant mounting station 104 by instructions of a human worker on self-moving assets 112A, 112B, 114, 116, 118, 120 in accordance with at least one embodiment. The method 300 will be described with reference to an example implementation of the plant mounting station configuration system 102. As will be appreciated in view of the disclosure, the order of the operations within the method 300 is not limited to the sequential execution illustrated in FIG. 3, but may be performed in one or more varying order(s), depending on applicability and in accordance with the present disclosure.At 302, the plant operating system 106 identifies a type of vehicle product for production in the vehicle manufacturing plant 100. Examples of vehicle product types include a sedan and a pick-up truck. In various embodiments, the vehicle product type specifies a vehicle model. At 304, the plant operating system 106 confirms availability of resources needed for the production of the vehicle product type. Examples of resources include station equipment, tools, materials, kit parts and workers.At 306, a configuration of a plant mounting station 104 is changed via instructions from human workers transmitted to one or more self-propelled assets 112A, 112B, 114, 116, 118, 120 of the plant mounting station 104. Examples of self-propelled articles 112A, 112B, 114, 116, 118, 120 include, but are not limited to, an AMR with equipment 112A, 112B, an AMR with hoist 114, an AMR with parts 116 mounted, an AMR with lighting 118, and an AMR with parts 120.At 308, the plant assembly station configuration system 102 receives the plant sensor data generated by a plant sensor system 108. In at least one embodiment, system mounting station digital twin generator 206 receives system sensor data generated by a system sensor system 108. The plant sensor system 108 includes a plurality of plant sensors distributed throughout the vehicle manufacturing plant 100. The plant sensor system 108 is configured to generate plant sensor data associated with the configuration of the plant mounting station(s) 104 for the plant mounting station configuration system 102.At 310, the plant mounting station configuration system 102 generates a digital twin of the plant mounting station 104DT based on the plant sensor data. In at least one embodiment, system mounting station digital twin generator 206 generates system mounting station digital twin 104 DT based on system sensor data. The digital twin of the plant mounting station 104DT is a virtual representation of the physical configuration of the plant mounting station 104. The plant sensor system 108 provides a perception infrastructure that acts as a link to mirror the physical configuration of the physical plant mounting station 104 into a digital twin of the plant mounting station 104DT in the plant mounting station configuration system 102.At 312, the plant mounting station configuration system 102 determines whether the changed configuration of the plant mounting station 104 meets the operating rules based on a digital twin evaluation of the plant mounting station 104DT. In at least one embodiment, based on a digital twin evaluation of plant mounting station 104DT, plant configuration evaluator 208 determines whether changed configuration of plant mounting station 104 meets operating rules. Examples of operating rules include safety rules and operation enables.When the plant mounting station configuration system 102 determines that the changed configuration of the plant mounting station 104 does not conform to the operating rules, the plant mounting station configuration system 102 generates an operability status indicating that the plant mounting station 104 is inoperative (314). In at least one embodiment, upon determining that changed configuration of plant mounting station 104 does not meet operating rules, plant configuration evaluator 208 generates an operability status indicating that plant mounting station 104 is inoperative at 314. The method 300 returns to 306.If the plant mounting station configuration system 102 determines that the changed configuration of the plant mounting station 104 meets the operating rules, the plant mounting station configuration system 102 generates an operability status indicating that the plant mounting station 104 is operable at 316. In at least one embodiment, when plant configuration evaluator 208 determines that changed configuration of plant mounting station 104 meets operating rules, plant configuration evaluator 208 generates an operability status indicating that plant mounting station 104 is operable at 316. The inspection of the equipment mounting station 104 based on the digital twin evaluation of the equipment mounting station 104DT by the equipment mounting station configuration system is completed, and the manufacturing process for the vehicle product type is started up.FIG. 4 illustrates a flow diagram of a method 400 for automatically configuring a plant mounting station 104 via the plant operating system 106, which provides instructions to self-moving assets 112A, 112B, 114, 116, 118, 120 according to at least one embodiment. The method 400 will be described with reference to an example implementation of the plant mounting station configuration system 102. As can be appreciated in view of the disclosure, the order of the method 400 is not limited to the sequential execution illustrated in FIG. 4, but may be executed in one or more varying orders as applicable and consistent with the present disclosure.At 402, the plant operating system 106 identifies a vehicle product type for production in the vehicle manufacturing plant 100. Examples of vehicle product types include a sedan and a pick-up truck. In various embodiments, the vehicle product type specifies a vehicle model. At 404, the plant operating system 106 confirms availability of resources needed for the production of the vehicle product type. Examples of resources include station equipment, tools, materials, kit parts and workers.At 406, the plant mounting station configuration system 102 receives the plant sensor data generated by a plant sensor system 108. In at least one embodiment, digital twin generator 206 of plant assembly station receives plant sensor data generated by plant sensor system 108. The plant sensor system 108 includes a plurality of plant sensors distributed throughout the vehicle manufacturing plant 100. The plant sensor system 108 is configured to generate plant sensor data associated with the configuration of the plant mounting station 104 for the plant mounting station configuration system 102. In at least one embodiment, plant sensor data is associated with location of one or more plant structures 124 in vehicle manufacturing plant 100. In at least one embodiment, plant sensor data is associated with one or more fixed items of equipment of plant mounting station 104. An example of a fixed item of matter is the fixed equipment 122. In at least one embodiment, plant sensor data is associated with location of one or more self-moving assets 112A, 112B, 114, 116, 118, 120 of plant mounting station 104. Examples of self-propelled articles 112A, 112B, 114, 116, 118, 120 include, but are not limited to, an AMR with equipment 112A, 112B, an AMR with hoist 114, an AMR with parts 116 mounted, an AMR with lighting 118, and an AMR with parts 120.At 408, the plant mounting station configuration system 102 generates a digital twin of the plant mounting station 104DT based on the plant sensor data and the vehicle product type that conforms to the operating rules. In at least one embodiment, digital twin generator 206 of plant mounting station 104DT generates a digital twin of plant mounting station 104DT based on plant sensor data and vehicle product type that meets operating regulations. Examples of operating rules include safety rules and operating distances. At 410, the plant mounting station configuration system 102 transmits the digital twin configuration of the plant mounting station 104DT to the plant operating system 106.At 412, the plant operating system 106 implements a configuration of the plant mounting station 104 in accordance with the digital twin configuration of the plant mounting station 104DT via instructions provided from the plant operating system 106 to the self-moving assets 112A, 112B, 114, 116, 118, 120 of the plant mounting station 104. Upon receiving the instructions, each self-propelled item 112A, 112B, 114, 116, 118, 120 moves to the corresponding location in the vehicle manufacturing plant 100 to automatically configure the plant mounting station 104.At 414, the plant mounting station configuration system 102 receives the feedback of plant sensor data generated by the plant sensor system 108. In at least one embodiment, system mounting station digital twin generator 206 receives system sensor data feedback generated by a system sensor system 108. The plant sensor data provides feedback about the configuration of the plant mounting station 104 generated in response to the instructions the plant operating system 106 provides to the self-moving assets 112A, 112B, 114, 116, 118, 120 of the plant mounting station 104.At 416, the plant mounting station configuration system 102 generates a digital twin of the plant mounting station 104DT based on the feedback of the plant sensor data. In at least one embodiment, system mounting station digital twin generator 206 generates system mounting station digital twin 104 DT based on system sensor data feedback. At 418, the plant mounting station configuration system 102 determines whether the configuration of the plant mounting station 104 meets the operating rules based on a digital twin evaluation of the plant mounting station 104DT. In at least one embodiment, based on a digital twin evaluation of plant mounting station 104DT, plant configuration evaluator 208 determines whether configuration of plant mounting station 104 meets operating rules.If the plant mounting station configuration system 102 determines that the configuration of the plant mounting station 104 does not conform to the operating rules, the plant mounting station configuration system 102 generates an operability status indicating that the plant mounting station 104 is inoperative at 420. In at least one embodiment, at 420, if system mounting station 104 configuration determines that system mounting station 104 configuration does not meet operating rules, system configuration evaluator 208 generates an operability status indicating that system mounting station 104 is inoperative. Method 400 returns to 412,If the plant mounting station configuration system 102 determines that the configuration of the plant mounting station 104 meets the operating rules, the plant mounting station configuration system 102 generates an operability status indicating that the plant mounting station 104 is operational at 422. In at least one embodiment, upon determining that configuration of plant mounting station 104 meets operating rules, plant configuration evaluator 208 generates an operability status indicating that plant mounting station 104 is operational at 422. The verification of the equipment mounting station 104 based on the digital twin evaluation of the equipment mounting station 104DT is completed and the manufacturing process for the vehicle product type is started.FIG. 5 shows a schematic illustration of examples 500, 502, 504 of various levels of reconfigurations of a plant mounting plant 104 that may be facilitated by a plant mounting station configuration system 102 in accordance with at least one embodiment. The plant mounting station 104 in each example 500, 502, 504 is similar to the plant mounting station 104 in FIG. 1. In each example 500, 502, 504, the plant mounting station 104 includes autonomous mobile robots (AMR) with equipment 112A, 112B, 112C, an AMR with hoist 114, an AMR with parts 116 mounted, an AMR with lighting 118, an AMR with parts 120, fixed equipment 122, and a plant structure 124.The first example 500 illustrates the reconfiguration of a low-level plant mounting station 104. The angle of the AMR with portions 120 was changed. The location of the AMR with hoist 114 was swapped with the location of the AMR with lighting 118. The AMR with equipment 112B was moved. In at least one embodiment, low-level reconfiguration of plant mounting station 104 is performed by instructions of human worker to self-moving assets 112A, 112B, 114, 116, 118, 120. In at least one embodiment, low-level reconfiguration of plant mounting station 104 is implemented by automatic reconfiguration of plant mounting station 104 via instructions of plant operating system 106 to self-moving assets 112A, 112B, 114, 116, 118, 120.The plant mounting station configuration system 102 receives plant sensor data from the plant sensor system 108. The plant sensor data provides information about the low-level reconfiguration of the plant mounting station 104. The plant mounting station configuration system 102 generates a digital twin of the reconfigured plant mounting station 104DT based on the plant sensor data. The plant mounting station configuration system 102 performs a simulation-based digital twin evaluation of the plant mounting station 104DT to determine whether the reconfigured plant mounting station 104 meets operating rules.When the equipment mounting station configuration system 102 determines that the reconfigured equipment mounting station 104 complies with the operating rules based on the digital twin evaluation of the reconfigured equipment mounting station 104 DT, the equipment mounting station configuration system 102 generates an operability status of the reconfigured equipment mounting station 104 as operable. When the equipment mounting station configuration system 102 determines that the reconfigured equipment mounting station 104 does not conform to the operating rules based on the digital twin evaluation of the reconfigured equipment mounting station 104 DT, the equipment mounting station configuration system 102 generates an operability status of the reconfigured equipment mounting station 104 as being inoperative.When the plant mounting station configuration system 102 has determined that the operability status of the reconfigured plant mounting station 104 is inoperative, additional modifications are implemented via instructions issued to the self-moving assets 112A, 112B, 114, 116, 118, 120 of the plant mounting station 104 to attempt to conform the configuration of the plant mounting station 104 to the operating rules, and the process described above is repeated. The instructions are either instructions of the human worker or instructions of the plant operating station 106.The second example 502 illustrates a mid-level reconfiguration of a plant mounting station 104. The AMR with parts 120 was removed from the equipment mounting station 104. The AMR with equipment 112B was removed and replaced with another AMR with equipment 112C. In at least one embodiment, mid-level reconfiguration of plant mounting station 104 is performed by instructions of a human worker on self-propelled assets 112A, 112B, 114, 116, 118, 120. In at least one embodiment, mid-level reconfiguration of plant mounting station 104 is implemented by automatic reconfiguration of plant mounting station 104 via instructions of plant operating system 106 to self-moving assets 112A, 112B, 114, 116, 118, 120.The plant mounting station configuration system 102 receives plant sensor data from the plant sensor system 108. The plant sensor data provides information about the mid-level reconfiguration of the plant mounting station 104. The plant mounting station configuration system 102 generates a digital twin of the reconfigured plant mounting station 104DT based on the plant sensor data. The plant mounting station configuration system 102 performs a simulation-based digital twin evaluation of the plant mounting station 104DT to determine whether the reconfigured plant mounting station 104 meets operating rules. When the equipment mounting station configuration system 102 determines that the reconfigured equipment mounting station 104 complies with the operating rules based on the digital twin evaluation of the reconfigured equipment mounting station 104 DT, the equipment mounting station configuration system 102 generates an operability status of the reconfigured equipment mounting station 104 as operable. When the equipment mounting station configuration system 102 determines that the reconfigured equipment mounting station 104 does not conform to the operating rules based on the digital twin evaluation of the reconfigured equipment mounting station 104 DT, the equipment mounting station configuration system 102 generates an operability status of the reconfigured equipment mounting station 104 as being inoperative.When the plant mounting station configuration system 102 has determined that the operability status of the reconfigured plant mounting station 104 is inoperative, additional modifications are implemented via instructions issued to the self-moving assets 112A, 112B, 114, 116, 118, 120 of the plant mounting station 104 to attempt to conform the configuration of the plant mounting station 104 to the operating rules, and the process described above is repeated. The instructions are either instructions of the human worker or instructions of the plant operating station 106.The third example 506 illustrates the high level reconfiguration of a plant mounting station 104. The entire plant assembly station 104 has been moved from a first location to a second location in the vehicle manufacturing plant 100. In at least one embodiment, superordinate reconfiguration of plant mounting station 104 is implemented by instructions of a human worker to self-moving assets 112A, 112B, 114, 116, 118, 120. In at least one embodiment, superordinate reconfiguration of plant mounting station 104 is implemented by automatic reconfiguration of plant mounting station 104 using instructions of plant operating system 106 to self-moving articles 112A, 112B, 114, 116, 118, 120.The plant mounting station configuration system 102 receives plant sensor data from the plant sensor system 108. The plant sensor data provides information about the displaced plant mounting station 104. The plant mounting station configuration system 102 generates a digital twin of the displaced plant mounting station 104DT based on the plant sensor data. The plant mounting station configuration system 102 performs a simulation-based digital twin evaluation of the displaced plant mounting station 104DT to determine whether the displaced plant mounting station 104 meets operating rules.When the plant mounting station configuration system 102 determines that the plant mounting station 104 is conforming to the operating regulations based on the digital twin evaluation of the laid plant mounting station 104 DT, the plant mounting station configuration system 102 generates an operability status of the laid plant mounting station 104 as operable. When the plant mounting station configuration system 102 determines that the plant mounting station 104 does not meet the operating regulations based on the digital twin evaluation of the laid plant mounting station 104 DT, the plant mounting station configuration system 102 generates an operability status of the laid plant mounting station 104 as being inoperative.When the plant mounting station configuration system 102 has determined that the laid plant mounting station 104 does not have an operability status, additional modifications are implemented via instructions to the self-moving assets 112A, 112B, 114, 116, 118, 120 of the plant mounting station 104 to attempt to conform the configuration of the laid plant mounting station 104 to the operating rules, and the process described above is repeated. The instructions are either instructions of the human worker or instructions of the plant operating station 106.In various embodiments, the plant mounting station configuration system 102 is configured to generate a digital twin of a new plant mounting station 104 in accordance with operating rules. The plant mounting station configuration system 102 is configured to transmit the digital twin of the new plant mounting station 104 to the plant operating system 106. The plant operating system 106 transmits instructions to the self-moving assets 112A, 112B, 114, 116, 118, 120 to configure a new plant mounting station 104 according to the digital twin configuration of the new plant mounting station 104. The use of a plant mounting station configuration system 102 in the configuration / reconfiguration of plant mounting stations 104 in a vehicle manufacturing plant 100 enables a physical manufacturing operation layout to be efficiently designed, verified, and replicated within a mounting location in a vehicle manufacturing plant 100. Making modifications to the plant mounting stations 104 using digital twin verification in a plant mounting station configuration system 102 enables real-time adjustments to the plant mounting stations 104.The plant mounting station configuration system 102 evaluates modifications to the plant mounting stations 104 via a central controller that prioritizes and coordinates the modifications within the plant mounting stations 104. Based on the type of vehicle, the digital twin (virtual copy) of a vehicle manufacturing plant 100 may be used to evaluate the overall floor environment and to change the placement of equipment and tools, material, physical solid structures, and other assets, or to make recommendations for more efficient configurations. Commissioning can be efficiently performed by self-moving assets 112A, 112B, 114, 116, 118, 120 and confirmed by the perception infrastructure system as defined by the plant sensor system 108 and the digital twin evaluation of the vehicle manufacturing plant 100.The plant assembly station configuration system 102 enables reconfiguration of the layout of a self-moving asset manufacturing operation and digital twin inspection. The perception infrastructure (cameras, sensors, and software) acts as a link to mirror the physical plant mounting station 104 into a digital twin of the plant mounting station 104DT. The digital twin of the plant mounting station 104DT may be used to check the manually or automatically changed layout of the plant mounting station 104 and to cause changes to the plant mounting stations 104 based on operating rules. The self-propelled articles can be reconfigured by changing their position or orientation in the plant mounting station 104.

Claims

A method (400) of automatically configuring a plant mounting station (104) in a vehicle manufacturing plant (100), comprising: identifying (402) a vehicle product type for production in the vehicle manufacturing plant (100); receiving (406) plant sensor data generated by a plant sensor system (108), the plant sensor data associated with a configuration of a first plant mounting station (104) in the vehicle manufacturing plant (100); generating (408) a digital twin (104 DT) of the first plant mounting station (104) based in part on the plant sensor data and the vehicle product type and conforming to operating rules; transmitting (410) a configuration of the digital twin (104 DT) to a plant operating system (106); converting (412) a configuration of the plant mounting station (104) in accordance with the configuration of the digital twin (104DT) by modifying at least one self-moving item (112A, 112B, 114, 116, 118, 120, 122) of the plant mounting station (104) via instructions provided from the plant operating system (106) to the at least one self-moving item (112A, 112B, 114, 116, 118, 120) of the plant mounting station (104), the instructions comprising at least one of a change in the orientation of the item (112A, 112B, 114, 116, 118, 120, 122), a change in the location of the item (112A, 112B, 114, 116, 118, 120, 122), the swap of a position of a first item (112A, 112B, 114, 116, 118, 120, 122) having a position of a second item (112A, 112B, 114, 116, 118, 120, 122), exchanging the at least one item (112A, 112B, 114, 116, 118, 120, 122), adding an item (112A, 112B, 114, 116, 118, 120, 122), and removing an item (112A, 112B, 114, 116, 118, 120, 122) to automatically configure the plant mounting station (104); receiving (414) a feedback of plant sensor data generated by the plant sensor system (108), the plant sensor data providing a feedback of the configuration of the plant mounting station (104) generated in response to the instructions the plant operating system (106) provides to the at least one self-moving item (112A, 112B, 114, 116, 118, 120) of the plant mounting station (104); generating (416) a digital twin (104 DT) of the plant mounting station (104) based on the feedback of the plant sensor data; determining (418) whether the configuration of the first plant mounting station (104) matches the operating rules based on a simulation-based evaluation of the digital twin (104 DT) of the first plant mounting station (104); generating (420, 422) an operability status of the configuration of the first equipment mounting station (104) based on the determination.A plant mounting station configuration system (102) comprising: at least one processor (200); and at least one memory (202) communicatively coupled to the at least one processor (200), the at least one memory (202) comprising instructions that, when executed by the at least one processor (200), cause the at least one processor (200) to perform the method of claim 1.The plant mounting station configuration system (102) of claim 2, wherein each of the plurality of self-propelled goods (112A, 112B, 114, 116, 118, 120) is one of an autonomous mobile robot, AMR, with plant equipment (112A, 112B), an AMR with parts (120), an AMR with hoist (114), an AMR with parts (116) mounted, and an AMR with station lighting (118).

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